Energy-Emitting Cutting Elements for Hard Formation Drilling

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Solution Overview

Problem

Drilling through harder geologic formations increases wear on drill bits and cutting elements, leading to reduced operational lifetime and increased costs due to higher risk of failure and longer retrieval times.

Innovation Solution

The use of energy-emitting cutting elements with a port and focused energy sources, such as lasers, to weaken formations by heating or expanding materials, allowing for mechanical removal with reduced wear on the cutting elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional mechanical cutting elements are used to drill through harder geologic formations, then the drilling capability is maintained, but wear on the cutting elements increases significantly

Engineering Contradiction:

Improvedrilling capabilityVSAvoidwear on cutting elements

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by using a focused energy source (laser) to pre-heat and weaken the formation material before the mechanical cutting element engages. This pre-conditioning of the formation reduces the hardness and strength of the rock, allowing the cutting element to remove material with significantly reduced wear while maintaining drilling capability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent partially replaces the purely mechanical cutting system with a thermal field (laser energy). The laser heating softens or weakens the formation material, substituting some of the mechanical cutting action with thermal softening, thereby reducing the mechanical stress and wear on the cutting elements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If conventional mechanical cutting elements are used in harder formations, then drilling continues, but operational lifetime of cutting elements is reduced

Engineering Contradiction:

Improvedrilling continuityVSAvoidoperational lifetime of cutting elements

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

By pre-heating and weakening the formation with laser energy before mechanical cutting occurs, the cutting elements experience reduced stress and wear, thereby extending their operational lifetime while maintaining continuous drilling productivity through harder formations.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If conventional mechanical cutting elements are used in harder formations, then drilling proceeds, but risk of failure increases

Engineering Contradiction:

Improvedrilling operationVSAvoidrisk of cutting element failure

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The laser pre-heating weakens the formation structure before mechanical cutting, reducing the peak forces and shocks experienced by the cutting elements. This preliminary weakening of the formation reduces the risk of sudden cutting element failure while maintaining drilling operation.

Inventive Principle:

Principle #10Preliminary action

4Productivity

If conventional mechanical cutting elements are used in harder formations, then drilling continues, but retrieval and replacement time increases

Engineering Contradiction:

Improvedrilling operationVSAvoidretrieval and replacement time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

By pre-weakening the formation with laser energy, the cutting elements experience reduced wear and extended operational lifetime, which directly reduces the frequency of retrieval and replacement operations, thereby decreasing the total time lost to these maintenance activities.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach extends the operational lifetime of drill bits and cutting elements by reducing wear and increasing efficiency in drilling through hard formations, thereby decreasing costs and time associated with retrieval and replacement.

Implementation Method 1

The energy source may be a laser or other focused energy source. The energy source may weaken the formation by heating, expanding, or otherwise energizing a portion of the formation

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

The energy source may weaken the formation by heating, expanding, or otherwise energizing a portion of the formation

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10655401B2Energy-emitting bits and cutting elements

Publication Date: 2020.05.19 SCHLUMBERGER TECH CORP

AI summary

A cutting element has a port extending through at least a portion of the cutting element body. A cutting face of the cutting element includes an ultrahard material. The port is configured to provide fluid communication therethrough and to direct focused energy from a focused energy source through the cutting element toward a formation proximate the cutting face.